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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 19 records

Critically assessing sodium-ion technology roadmaps and scenarios for techno-economic competitiveness against lithium-ion batteries

Sodium-ion batteries have garnered notable attention as a potentially low-cost alternative to lithium-ion batteries, which have experienced supply shortages and price volatility for key minerals. Here we assess their techno-economic competitiveness against incumbent lithium-ion batteries using a modelling framework incorporating componential learning curves constrained by minerals prices and engineering design floors. We compare projected sodium-ion and lithium-ion price trends across over 6,000 scenarios while varying Na-ion technology development roadmaps, supply chain scenarios, market penetration and learning rates. Assuming that substantial progress can be made along technology roadmaps via targeted research and development, we identify several sodium-ion pathways that might reach cost-competitiveness with low-cost lithium-ion variants in the 2030s. In addition, we show that timelines are highly sensitive to movements in critical minerals supply chains—namely that of lithium, graphite and nickel. Our modelled outcomes suggest that being price advantageous against low-cost lithium-ion variants in the near term is challenging and increasing sodium-ion energy densities to decrease materials intensity is among the most impactful ways to improve competitiveness.

25 ENERGY STORAGE↗

On falling film evaporator – A review of mechanisms and critical assessment of correlation on a horizontal tube bundle with updated development

Optimization of the energy efficiency and reduction of the greenhouse gas emission for the heat pump system is imperative to meet the net-zero goals at 2050. Chillers with falling film evaporator design not only possess better system performance but also contain less refrigerant inventory. Hence, accurate prediction of the evaporator performance is pivotal especially when charged with low-GWP refrigerant. Here, the study reviews the correlations for falling film evaporator with a horizontal tube bundle configuration. The major efforts of this study include four tasks: (a) literature review of the experimental studies and available empirical correlations; (b) comprehensive discussion of the falling film evaporation heat transfer mechanism; (c) development of a new rationally based correlation based on available literature; and (d) comparison of different correlations based on the existing data. The collected data includes 4114 data points from 8 sources, 6 refrigerants (R-600a, R-290, R-245fa, R-134a, R-1234ze(E), R-123), 5 types of the tubes (Plain, Turbo-GII-HP, GEWA-B, Low-fin, High-Flux), liquid Weber number from 2.2 × 10 –6 to 0.7, imposed vapor Weber number from 0 to 37.2, heat flux from 2.5 to 151.5 kW/m 2 , and film Reynolds number from 1 to 3159.8. The new correlation gives a MAD of 28.3%, and an R 2 of 0.86. Yet, the developed correlation considers various heat transfer mechanisms, including the transition point from falling film evaporation to the nucleate boiling, local evaporation, dry-out, mist flow, imposed flow, and enhanced tube effects.

42 ENGINEERING↗

Critical Assessment of Electronic Structure Descriptors for Predicting Perovskite Catalytic Properties

The discovery and design of materials which can efficiently catalyze the oxygen reduction and evolution reactions at reduced temperatures is important for facilitating the widespread adoption of fuel cell and electrolyzer technologies. Numerous studies have produced correlations between catalytic properties, such as oxygen surface exchange or electrode area specific resistance (ASR), and properties of the catalyst material. However, correlations have historically been limited in scope (e.g., using only a few materials or at a single temperature) and it has been difficult to provide detailed assessments of their robustness. Here, in this study, we assess the ability of the O p-band center electronic structure descriptor, obtained from density functional theory (DFT) calculations, to correlate with oxygen surface exchange rates, diffusivities, and area specific resistances for a large database of perovskite oxide catalytic properties. By data mining the literature, we obtain 747 catalytic property value data points spanning 299 unique perovskite compositions from 313 studies. We assess linear correlations of each property with the O p-band center and find generally modest correlations that are qualitatively useful (prediction mean absolute errors of about 0.5 log units are typical), where the correlations are improved at higher temperatures (e.g., 800 °C vs. 500 °C) and significantly improve when considering fits to the subset of materials which have multiple independent measurements. These findings suggest that the spread of property data is significantly influenced by experimental uncertainty, and subsequent measurements of additional materials will likely improve the O p-band center correlations.

30 DIRECT ENERGY CONVERSION↗

Critical assessment of the recent report on the gigaparsec-scale correlation of the orientations of large quasar groups

ABSTRACT Recently, it was reported that large quasar groups (LQGs) identified from the Sloan Digital Sky Survey (SDSS) data release seven catalogue are not randomly oriented but preferentially aligned or orthogonal over scales 1–2 Gpc. To confirm this claim, I reproduced the same LQG sample and performed Sobolev tests of uniformity on the LQG orientation axes in the redshift space. Contrary to the original report based on the bimodal distribution of the LQG position angles in the sky, I found no departure from uniformity in the distribution of the LQG orientation axes. I also examined whether the LQGs are physical structures using a statistically more reliable data set constructed from the SDSS data release 16 (DR16) large-scale structure (LSS) quasar catalogue. Considering the Gaussian primordial density fluctuations and shot noise, I estimated the mass density contrasts of the LQGs from the number counts of the DR16 LSS quasars and found that most of the LQGs do not trace statistically significant high-density regions. I conclude that the LQG sample is a collection of unphysical chance associations and should not be used for any cosmological studies.

Fujii, Hirokazu (ORCID:0000000161473512)↗

Assessing Critical Conditions for Scour Near Obstructions using Bed Shear, Particle Onset of Motion Balances, and CFD-DEM Modeling of Granular Beds

Computational Fluid Dynamics combined with a Discrete Element Method is one of the computational methods that can be used to model multiphase flows. In this method various phases, gas and liquid or solid, are present in the same computational domain. The local averaged Navier–Stokes equations determine the flow of the continuous phase fluid and are solved using the traditional CFD finite volume approach. DEM is based on a Lagrangian formulation, which solves the equations of motion, expressed in ordinary differential equations, for representative particles as they move in space and time. The interactions between the continuous fluid phase and discrete solid phase are modeled with the use of Newton’s laws of motion via drag force. The particles interact with each other and with the boundaries of the fluid continuum, and the resulting contact forces are included in the equations of motion. The properties of solid particles and boundaries are treated as elastic bodies, with specified density, elastic modulus, and Poisson’s ratio. Particle shapes may vary from single spherical particles to more complex-shaped composite particles. The particles may be introduced into the domain by random or structured injection at a point, surface, or volume, depending on the application. More details on the formulation can be found in the Simcenter STAR-CCM+ User’s Manual and OpenFOAM website.

97 MATHEMATICS AND COMPUTING↗

Microreactor Assembly Transportation Cask Model Description for Criticality Safety Validation Basis Assessment

Criticality safety analyses are completed on a transportation cask used for microreactor assembly shipment to provide an example of model and analysis to industry for reproducing this type of study on their microreactor fuel shipment. The fuel assembly considered is based on a gas-cooled microreactors (GC-MR), which utilizes HALEU fuel in the form of TRISO particles and utilizes various design options considered in industry designs. Various versions of this GC-MR assembly were studied, with and without YH 2 moderator, providing similar conclusions.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Microreactor Assembly Transportation Cask Model Description for Criticality Safety Validation Basis Assessment

Criticality safety analyses are completed on a transportation cask used for microreactor assembly shipment to provide an example of model and analysis to industry for reproducing this type of study on their microreactor fuel shipment. The fuel assembly considered is based on a gas-cooled microreactor (GC-MR), which utilizes HALEU fuel in the form of TRISO particles and utilizes various design options considered in industry designs. Various versions of this GC-MR assembly were studied, with and without YH2 moderator, providing similar conclusions. The shipment cask design is revised based on an existing design ES-3100, developed by Y-12 for the transport of highly enriched uranium (HEU), but is enlarged to hold the GC-MR fuel assembly. Criticality safety analysis for the cask/GC-MR fuel assembly package was performed using the CSAS6 sequence of SCALE6.3.2, utilizing the ENDF/B-VII.1 based continuous energy neutron library, and the analysis strictly follows the guideline from NRC reference reports. Different scenarios, e.g. normal operation, undamaged cask with water flooded, damaged cask with optimal water moderation, have been analyzed and it could be concluded the package would always have a large margin of subcriticality even packed in an infinite array. Sensitivity and similarity analyses are also performed using the TSUNAMI sequence of SCALE6.3.2, and the similarity analysis uses all the experiments from the ICSBEP Handbook with Intermediate and Mixed Enriched Uranium (IEU) and Low Enriched Uranium (LEU) systems together with additional ones that are sponsored by the DNCSH program. These similarity analyses indicate that dry cases have no similar benchmark experiments (ck values greater than 0.8), which may become problematic if more assemblies are shipped together (or a fully loaded core is shipped) and margin to criticality is reduced. However, the damaged cask models with flooded assemblies exhibited similarities to many experiments with ck values greater than 0.8.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Arctic Critical Infrastructure: Assessing and Predicting the Risk to Critical Permafrost Infrastructure from Climate Change: A New Thermomechanical Approach

This study presents the development of a computational framework designed to predict the interaction between permafrost and infrastructure, addressing potential failure modes and mitigation strategies in the context of climate change. The framework, rooted in advanced modeling and simulation (mod/sim) techniques, integrates thermomechanical coupling to account for the complex interplay between heat flow, ice content, and mechanical behavior in permafrost. Existing models fail to fully capture these dynamics, particularly as they relate to the effects of ice saturation on structural integrity. Our innovative Arctic Coastal Erosion (ACE) framework fills this gap by coupling thermal and mechanical models to accurately simulate subsidence and deformation in permafrost environments. We applied the ACE framework to a representative runway, demonstrating its capability to predict settlement due to rising temperatures and subsequent permafrost thaw. This proof-of-concept showcases the potential of the framework to evaluate risks to Arctic infrastructure, which supports over four million people and 70% of existing permafrost-based structures. By simulating various infrastructure types and environmental conditions, our research offers insights into failure mechanisms and evaluates structural solutions to mitigate risk. The anticipated deliverables, including a prototype runway exemplar, position this project as a critical advancement in permafrost infrastructure modeling, with applications in national security and resilience planning.

54 ENVIRONMENTAL SCIENCES↗

Internal Collaboration on Recent Nuclear Criticality Safety Assessments

Prevention of inadvertent criticality at facilities with large quantities of fissionable materials is one of the most important requirements those facilities grapple with. Given that criticality cannot be mitigated, only eliminated, a hard line must be taken on this requirement. The facilities and sites with the possibility of such an event must abide by a plethora of requirements, most stemming from the ANSI/ANS-8 series of consensus standards. One such standard, ANSI/ANS-8.19, Administrative Practices for Nuclear Criticality Safety, gives requirements and recommendations necessary for establishing a nuclear criticality safety program for a given facility or site. One of those requirements includes periodic assessments of the NCS program. To meet the assessment requirement, Los Alamos National Laboratory (LANL) conducts periodic assessments on individual facilities and overall programmatic health aspects. The teams developed to perform these assessments include people both inside and outside the LANL NCS program. Recently, the Nuclear Criticality Safety Division and the Critical Experiments Team of the Advanced Nuclear Technology Group established a collaboration to aid in fulfilling the assessment requirement.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

A Multi-scale, Geo-data Science Method for Assessing Unconventional Critical Mineral Resources

Critical minerals (CM) supply raw materials that constitute many of our essential infrastructure, defense, technology, and electrification needs. Currently, production and refinement of these materials from conventional sources is limited to few regions globally, which makes supply of these resources particularly venerable to disruption. To help overcome these risks and meet growing demand, attention has focused on identifying and developing resource potential of unconventional geologic CM sources, such as rare-earth elements in sedimentary systems. However, the unconventional nature of these types of sources means they are often poorly characterized and/or under-explored with respect to conventional counterparts. We present a regional case study for an Unconventional Rare-earth and Critical minerals (URC) assessment method for predicting and identifying REE resource potential and occurrence in unconventional systems in the Central Appalachian Basin (CAB). The method utilizes a geologic and geospatial data-driven approach, informed and guided by knowledge of REE enrichment processes, to systematically predict and identify areas of higher enrichment. Results from the test case indicate locations with potential for different types of coal-REE deposits, demonstrating its utility for reducing the area of exploration and identifying sites for more detailed investigation. Building upon the regional scale assessment capability, ongoing science-based enhancements to the method will allow for finer-scale (e.g., mine-scale) predictions required to support technical and economic assessments.

Creason, Christopher↗

Vulnerabilities in Satellite Communications Underscore Threat to Critical Infrastructure

INL analysts assess critical infrastructure sectors leveraging satellite communications (SATCOM) are likely inadvertently increasing the attack surface caused by inherent vulnerabilities in equipment and communications pathways. A lack of ownership regarding security in SATCOM ecosystems creates pervasive information security risk, and the obfuscation of patching responsibility means the mitigation of publicly and privately disclosed vulnerabilities is difficult to track. With these factors in consideration, INL analysts assess the number of attacks against SATCOM is likely to increase in the next decade as threat actors exploit these vulnerabilities.

99 GENERAL AND MISCELLANEOUS↗

Critical statistical assessment of data in metal additive manufacturing

Obtaining high quality data reflecting the relationships between the additive manufacturing (AM) process parameters, material microstructure and mechanical properties is crucial for the use of machine learning in AM. A database of over 4,000 data entries of metal AM was created thanks to a large number of literature studies on key process parameters and indicators of build quality. Meta-analysis reveals critical biases in the literature. Firstly, majority of studies report only high quality builds, these imbalances in reporting result in weak correlation between process parameters, properties and consolidation, limiting the ability of machine learning models to generalize beyond optimized conditions. Nevertheless, the trained models accurately predict yield strength ($R^2 = 0.85$), suggesting that certain process–property relationships are effectively captured within these models. Secondly, quantitative microstructural data are largely absent, limiting the learning of the microstructure-mechanical properties relationships. Finally, current process window identification is based largely on the consolidation, despite significant uncertainty in its measurement. It is important to identify the process map on the basis of not only the consolidation, but also mechanical behaviour under loading. Such a identification shows that 316 L and Inconel have much larger process map (i.e. highly printable) in comparison to the AlSi10Mg and Ti6Al4V.

Additive manufacturing↗

Assessment of critical flaw sizes and crack driving forces during additive manufacturing of metallic materials

Additive manufacturing (AM) of complex engineering components is often plagued by a high susceptibility to cracking, particularly in high-strength metallic materials. While alloy design efforts have made progress in mitigating solidification defects, there remains a need for mechanistic guidelines to predict susceptibility to solid-state cracking. To address this gap, driving forces for the growth of melt pool cracks are calculated across a wide range of alloys using an efficient computational framework. Calculations are coupled with rapid single track laser experiments to elucidate trends in cracking from laser melting. The analyses conducted here highlight the important role of material properties in susceptibility to cracking, notably fracture toughness and elastic modulus. An important finding is that residual stresses that are limited in magnitude to the yield stress of the material are likely insufficient to drive cracking during cooling. Furthermore, the implications of these results are discussed in the context of alloy design for AM and residual stress accumulation during AM.

36 MATERIALS SCIENCE↗